2026-09-24

PCS2 Lite - Ancillary Bay (Remove and Install)

Correction code 16300500401 FRT 2.16 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Torque Specifications

Table 1. Torque Specifications:PCS2 Lite - Ancillary Bay (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x5) that attach the PCS2 Lite to the HV battery
15 Nm (11.1 lbs-ft) - 180 degrees
15 Nm (11.1 lbs-ft)
  • Skt, 1/4" Sq Dr, 8mm, HV Insulated
 Replace 1115833-00-B

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open all four doors and lower all four windows.
  3. Move the front seats forward.
  4. Start the thermal fill/drain routine.
    1. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
    2. Unlock the vehicle gateway. See Gateway Unlock.
    3. Tap the Service Mode "wrench" at the bottom of the touchscreen UI, and then tap Thermal > Actions > Start Thermal Fill/Drain, and select Run to start the routine.
      Note
      This routine has a 5-hour limit. After 5 hours, this routine must be performed again.
  5. Disconnect the LV power. See GUID-C392D1B4-3007-45A4-A469-1B92676863F1.html.
  6. Remove the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  7. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  8. Position coolant drain container underneath LH rear of HV battery.
  9. Disconnect the rear drive unit inverter inlet tube from LH rear of HV battery.
    Note
    Plug hose connections as needed. Coolant loss greater than 1 L will require a vacuum fill.
  10. Attach the coolant drain hose adapter to PCS outlet hose coupling.
    Note
    Use adapter with 90 degree angle. Make sure the locking tab is fully seated and the valve is open.
  11. Connect the waste coolant container hose to the drain and fill adaptor.
    Note
    Push until an audible click is heard, then perform a push-pull-push test to verify the connection is fully seated.
  12. Position the coolant drain container underneath RH rear of vehicle.
  13. Disconnect rear powertrain supply hose from PCS inlet hose coupling.
    Note
    1x spring clip. Plug hose connections as needed. Coolant loss greater than 1 L will require vacuum fill.
  14. Connect the coolant leak test adapter to the PCS inlet hose coupling.
    Note
    Remove the rubber plug from the coupler if installed. Make sure the locking clip is fully seated.
  15. Connect the coolant leak test fixture outlet hose to leak test adapter.
  16. Connect the outlet hose to the leak test fixture tool.
  17. Close both valves on the coolant leak test fixture tool.
  18. Connect compressed air to coolant leak test fixture tool.
    Note
    Air supply source should be above 50 psi.
  19. Turn the inlet valve on leak test fixture tool clockwise to open it, turn on the digital gauge and set to "psi", and then adjust the regulator to 50 psi.
    Note
    Turn the regulator knob clockwise to increase pressure and counterclockwise to decrease pressure.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  20. Set the timer to 2 minutes.
  21. Slowly open the outlet valve on the leak test fixture tool until the valve knob is inline with the airline.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  22. Start the 2-minute timer. Once the timer is complete, select Stop Reset.
  23. Close both valves on the coolant leak test fixture tool.
  24. Disconnect the coolant leak test adapter with hose from the PCS inlet hose coupling, and disconnect the coolant drain and fill adapter with hose from the PCS outlet hose coupling.
  25. Attach coolant leak test adapter with hose to PCS outlet hose coupling.
    Note
    1x spring clip. Make sure the locking tab is fully seated.
  26. Attach coolant drain and fill adapter with extension hose to PCS inlet hose coupling.
    Note
    1x spring clip. Make sure the locking tab is fully seated.
  27. Repeat step 19 to step 23.
  28. Disconnect compressed air from the leak test fixture tool.
  29. Disconnect waste coolant container from the drain and fill adapter.
  30. Disconnect coolant drain and fill adapter from the PCS inlet hose coupling.
    Note
    Install plug to inlet hose coupling. If the battery is returned to Reman, remove the special tool plugs.
  31. Disconnect the coolant leak test fixture outlet hose from the leak test adapter.
  32. Disconnect the coolant leak test adapter from the PCS outlet hose coupling.
    Note
    1x spring clip
  33. Lower the vehicle until tires are touching the ground
  34. Remove the 2nd row seat cushion and disconnect the harness connectors. See Seat Cushion - 2nd Row (Remove and Replace).
  35. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Install).
  36. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  37. Use the rubber bands to secure the high voltage controller (HVC) to the body.
  38. Place absorbent sheets below and around the PCS2 Lite coolant inlet and outlet hoses to prevent excess coolant from dripping.
  39. Disconnect the PCS2 Lite coolant inlet hose from the PCS2 Lite by releasing the clips (x2) with the PCS Coolant Connector Removal Tool (1111868-00-B). Place an absorbent sheet under the hose to catch excess coolant, visually inspect for coolant residue and clean with a shop towel if needed. Install two plugs on the PCS2 Lite and hose, and discard the O-ring.
  40. Disconnect the PCS2 Lite coolant outlet hose from the PCS2 Lite by releasing the clips (x2) with the PCS Coolant Connector Removal Tool (1111868-00-B). Place an absorbent sheet under the hose to catch excess coolant, visually inspect for coolant residue and clean with a shop towel if needed. Install two plugs on the PCS2 Lite and hose, and discard the O-ring.
  41. Disconnect the AC filter harness connector from the PCS2 Lite.
    1. Fully release the red lock pin.
    2. Press the orange tab inward and lift the connector to remove it from the vehicle.
      Note
      If needed, use a plastic trim tool to assist with removal.
  42. Disconnect the HV DC harness connector from the PCS2 Lite by pulling the locking tab upward.
  43. Disconnect the PCS2 Lite logic connector from the PCS2 Lite.
  44. Disconnect the PCS2 Lite LV connector from the PCS2 Lite.
  45. Remove and discard the bolts (x5) that attach the PCS2 Lite to the HV battery.
    Note
    Ensure only the 8mm fasteners are removed; do not remove the T20 fasteners.
    Tip
    Use of the following tool(s) is recommended:
    • Skt, 1/4" Sq Dr, 8mm, HV Insulated
  46. Secure suction cups to the PCS2 Lite by pressing the plunger continuously until the red line is no longer visible.
  47. Lift the PCS2 Lite up and remove it from the ancillary bay by releasing the datums (x2) and slightly tilting the rear upward.
    Note
    Inspect for missing insulators underneath and install any if needed, then visually check for coolant residue and clean with a shop towel if necessary.

Install

  1. Align the datums (x2) into the PCS2 Lite holes, slightly tilt the rear upward and lower it into the ancillary bay.
    Note
    Ensure that all busbar insulators beneath PCS2 Lite are present.
  2. Remove suction cups from the PCS2 Lite.
  3. Install new bolts (x5) that attach the PCS2 Lite to the HV battery.
    15 Nm (11.1 lbs-ft) - 180 degrees
    15 Nm (11.1 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Skt, 1/4" Sq Dr, 8mm, HV Insulated
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 15 Nm.
  4. Connect the AC filter harness connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  5. Connect the PCS2 Lite LV connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  6. Connect the PCS2 Lite logic connector to the PCS2 Lite.
  7. Connect the HV DC harness connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  8. Connect the PCS2 Lite coolant inlet hose to the PCS2 Lite as follows:
    1. Remove 2 plugs from the coupling and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1803223-00-A).
    4. Align the hose to the coupling and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  9. Connect the PCS2 Lite coolant outlet hose to the PCS2 Lite as follows:
    1. Remove 2 plugs from the coupling and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1803223-00-A).
    4. Align the hose to the coupling and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  10. Release the bungee cords and position the HVC onto the PCS2 Lite.
  11. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  12. Remove the HVC logic cap.
  13. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  14. Connect the coolant leak test adapter plug to the PCS outlet hose coupling.
    Note
    Remove the rubber plug from PCS outlet hose coupling if present. Install 90 degree leak test adapter with NPT plug. Make sure the locking clip is fully seated.
  15. Connect the coolant leak test adapter to the PCS inlet hose coupling.
    Note
    Remove the rubber plug from PCS outlet hose coupling if present. Make sure the locking clip is fully seated.
  16. Connect the coolant leak test fixture outlet hose to leak test adapter.
  17. Connect the outlet hose to the leak test fixture tool.
  18. Close both valves on the coolant leak test fixture tool.
  19. Connect compressed air to coolant leak test fixture tool.
    Note
    Air supply source should be above 50 psi.
  20. Turn the inlet valve on leak test fixture tool clockwise to open it, turn on the digital gauge and set to "psi", and then adjust the regulator to 50 psi.
    Note
    Turn the regulator knob clockwise to increase pressure and counterclockwise to decrease pressure.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  21. Slowly open the outlet valve on the leak test fixture tool until the valve knob is inline with the airline.
    CAUTION
    Use caution as coolant may spill. Make sure to wear safety glasses.
  22. Allow the pressure in the PCS coolant loop to stabilize at 50 psi.
  23. Allow 110 seconds for the pressure to stabilize.
  24. Close the inlet valve on the coolant leak test fixture tool.
  25. Record the PCS coolant loop leak check starting pressure.
  26. Allow 240 seconds to test and then record the ending pressure value. The max delta between the start and end pressures is 0.5 psi.
    Note
    If the difference is greater than 0.5 psi, check the hose, adapter, and plug fittings, check the regulator pressure, then retest. If the difference is still greater than 0.5 psi, escalate a Toolbox session.
  27. Disconnect compressed air from the leak test fixture tool.
  28. Slowly open the inlet valve on the leak test fixture tool to discharge air from coolant system.
  29. Disconnect the coolant leak test fixture hose from the leak test adapter.
  30. Disconnect the coolant leak test adapter from the PCS inlet hose coupling.
  31. Position the coolant drain container underneath RH rear of vehicle.
  32. Connect the rear powertrain supply hose to the PCS inlet hose coupling.
    Note
    • Remove plugs and perform push-pull-push test to make sure hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  33. Disconnect the coolant leak test adapter plug from the PCS outlet hose coupling.
  34. Position coolant drain container underneath LH rear of the vehicle.
  35. Connect the RDU inverter inlet tube to PCS outlet hose coupling.
    Note
    • Remove plugs and perform push-pull-push test to make sure hose is fully engaged.
    • Coolant loss greater than 1 L will require vacuum fill.
  36. Remove the coolant drain container from underneath vehicle.
  37. Install the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  38. Perform a vacuum refill of the cooling system. See Cooling System - Vacuum Refill (Test/Adjust).
  39. Exit the Service Mode. See .
  40. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  41. Raise all windows and close all doors.
  42. Remove the vehicle from the lift.